1. automotive and vehicles
2. vehicle brands
3. acura

Range of Three Phase Intelligent Motor Controllers
2.2 – 630kW
Installation and
Commissioning Guide
Failure to read these instructions prior to installation and use
may result in damage to the starter and or the driven
equipment and may render the warranty invalid
A Revised Version of this manual may be available.
Contact +441326 567222 for details.
Integra 2.2-630 kW Version 3.0
January 2014
2
Index
PAGE
No.
6
6
7
8
9
10
11
12
13
14
15
15
16
17
17
17
17
18
20
20
20
21
21
21
21
21
21
22
22
22
22
23
23
23
24
25
26
27
CONTENTS
INTRODUCTION
The Problems with Induction Motors
Starting Induction Motors – The Integra Solution
Motor Efficiency – The Integra Solution
INTEGRA PRODUCT SPECIFICATIONS
Integra Selection Guide 2.2 to 90kW, 220 – 690V
Integra Selection Guide 75 to 630kW, 220 – 690V
Load and Duty Cycle Table
Integra Starting Duty Table
Sizing Integra for a Particular Duty
INSTALLATION
Safety Notice
Declaration of Conformity
Prior to Installation
Mechanical Installation
Wall Mounting
Mounting within an Additional Enclosure
Cooling Integra within an Additional IP54 Enclosure
Minimum Enclosure Size for Operation within an IP55 Enclosure
Heat Dissipation Table
Fan Selection Table
ELECTRICAL INSTALLATION
Supply Voltage Transients
Control Voltage Transients
Coil Suppression
Input / Output Control Connections
Harmonics
Point of Common Coupling (PCC)
Individual Motor Power Factor Correction Capacitors
Thermal Protection Switch
Additional Equipment
Protective Earth
Power Terminals Torque Setting
Fuse Protection
Power Connections Drawing – DOL Starter
Standard Control Circuit Requirements
Control Circuit Requirements for Reversing
Star (Wye) Delta Installation - Description of Operation
Suresense Technologies©
Integra 2.2-630 kW Version 3.0
January 2014
Index
27
28
30
32
32
33
33
33
33
34
34
35
35
35
35
36
36
36
35
45
37
38
42
42
40
40
40
40
41
43
43
43
43
44
44
44
47
48
49
Star (Wye) Delta Installation - Installing on a Compressor
Installing Integra in an Existing Star (Wye) Delta Starter
INSTALLING INTEGRA ON TWO SPEED TWO WINDING MOTORS
Power Connections for Two Speed Two Winding Motor
Control Connections for Two Speed Two Winding Motor
DESCRIPTION OF USER CONTROL SETTINGS
Mains Supply Voltage Selection
220 – 480V PCB Voltage Selection
525 - 690V PCB Voltage Selection
ACCESSING THE INTEGRA MENU
Basic User Menu Description of Parameters
Start Delay
Ramp Up Time
Pedestal Voltage
Ramp Down
Step Down Voltage
Energy Saving On/Off
Relay Functions 1&2
Load Response
Frequency Setting
PROCEDURE FOR ADJUSTING AND SAVING A PARAMETER
Main Menu
Rock Crusher Application
Slip Ring Motor Application
PARAMETER MENU EXTENDED SOFT START
Extended Soft Start Description of Parameters
Current Limit Level and Time
Kick Start Level and Time
APPLICATION SETS
Braking Torque Level and Time – Plug Braking
Zero Speed Detection – Plug Braking
Power Connections for Plug Braking
Control Connections for Plug Braking
DC BRAKING
Braking Torque Level and Time – Plug Braking
Zero Speed Detection – Plug Braking
Power Connections for Plug Braking
Control Connections for Plug Braking
PARAMETER MENU ENERGY SAVING MENU
Suresense Technologies©
3
Integra 2.2-630 kW Version 3.0
January 2014
Index
49
49
50
51
51
50
52
53
58
55
64
63
52
66
60
61
68
71
71
71
72
72
64
68
68
68
68
68
69
69
69
69
69
73
74
74
74
74
74
Voltage Limit
Optimum Efficiency
Dead Band
Slip Tolerance
Stall Compensation
Dwell Time
PARAMETER MENU INTELLIGENT CONTROL
Stored Energy
Stored Energy
Timed Power Off
Pump On/Pump Off
Eddy Drive
Proximity Sensor
PARAMETER MENU MORE EXTENDED SOFT START
Dual Ramp Profile 1
Dual Ramp Profile 2
MAIN MENU - SPECIAL PARAMETERS
Parameter Menu Input Function
Input 1 Function
Input 2 Function
Input 3 Function
Input 4 Function
Switch De-Bounce Timer
Voltage Control
Voltage Control Cycles
Voltage Control Correction
Voltage Control Pulse Width
Blocking Test
Conduction Test
Fault Timer
Phase Analysis
Fault Bypass
Cut Off Voltage
PARAMETER MENU OPTIONS MENU
Restore Default Parameter Settings
Software Version
Keypad Reaction Time
Fault History Erase
Fault History Interrogate
Suresense Technologies©
4
Integra 2.2-630 kW Version 3.0
January 2014
Index
75
75
75
76
76
77
78
79
79
79
79
81
COMMISSIONING
Pre- Commissioning Checks
Starting Integra
SERVICE AND MAINTENANCE
General
Fault Finding
Fault Finding Procedure Table
Testing and Replacing Thyristors
Thyristor Short Circuit Test
Thyristor Gate Test
Thyristor Removal and Replacement
DIMENSIONS
Suresense Technologies©
5
Integra 2.2-630 kW Version 3.0
January 2014
6
INTRODUCTION
THE PROBLEMS WITH INDUCTION MOTORS
Since its invention one hundred years ago, the standard 3-phase induction motor has
become one of the most familiar items of industrial equipment ever known. Due to its
simplicity of construction, low cost, reliability and relatively high efficiency, it is likely to
remain the prime source of mechanical energy for the foreseeable future.
The main problems are the motor’s inability to match motor torque to load torque both
during starting and running and the high starting current. During starting the motor
usually produces 150 - 200% torque (see Figure 1) accelerating the load to full speed in
a fraction of a second, which can cause damage to the drive train. At the same time the
motor can commonly draw 8 times nominal current (In) causing supply stability problems
(see Figure 2).
When the motor is operating at light load for extended periods the motor’s efficiency falls
due to the over-fluxing of the windings for the particular torque required to drive the load.
At a constant terminal voltage this flux, often referred to as magnetising current, is fixed
and accounts for around 30-50% of the motors total losses.
Figure 1
Motor Torque
Load Torque
Torque
Speed
Figure 2
100%
8 x (In)
Starting Current
Current
(In)
Speed
Suresense Technologies©
Integra 2.2-630 kW Version 3.0
January 2014
7
STARTING INDUCTION MOTORS - THE INTEGRA SOLUTION
In common with all soft start devices Integra uses Thyristors to accurately control the
voltage applied at the motor terminals.
A characteristic of the Thyristor to switch rapidly from "OFF" to "ON" when pulsed, and to
remain "ON" until the current through the device falls to zero at the end of each halfcycle in the AC supply, is called self-commutation.
By controlling the switch-on point relative to the voltage zero crossing in each half cycle
of the supply, it is possible to regulate the current flowing through the Thyristor. The
closer the turn-on point is to the end of the cycle the smaller the value of current that will
be allowed to flow. Conversely, the closer the turn-on point is to the beginning of the
cycle the higher the value of current will be. Using this principle and by connecting two
Thyristors in anti-parallel to each of the phase connections to a motor Integra can
continuously adjust the voltage to the motor terminals by precisely controlling the
Thyristors turn-on points. This provides just sufficient voltage for the motor to accelerate
the load. See Figure 3.
So, for instance, by starting with a large delay to the turn on point in each half cycle, and
progressively reducing it over a selected time period, the voltage applied to the motor
starts from a relatively low value and increases to full voltage. Due to the motor torque
being proportional to the square of the applied voltage, the starting torque increases in a
step less manner ensuring a soft start for both the motor and the driven load.
Figure 3
Motor Torque
Acceleration
Torque
Torque
Load Torque
Speed
Suresense Technologies©
100%
Integra 2.2-630 kW Version 3.0
January 2014
8
MOTOR EFFICIENCY – THE INTEGRA SOLUTION
When working at or near full load, the typical 3-phase induction motor is relatively
efficient, achieving efficiencies of between 80% to 92%. However, as shown in Figure 4
below, motor efficiency falls dramatically when the load falls to less than 50% of rated
output. In fact, very few motors actually experience consistent fully rated operation, the
vast majority operate at much lower loads due to either over-sizing (a very frequent
situation), or natural load variations.
In applications where motor speeds do not need to be varied, the optimisation software
in the Integra will produce energy savings in lightly loaded motors.
Less sophisticated soft-starters remain at full conduction and the motor then behaves as
if it were connected directly to the mains supply. However, at light loads at full mains
voltages, induction motors always have excess magnetising current (see Figure 5). By
detecting the load at any instant, and adjusting the motor terminal voltage accordingly,
Integra is able to save some of the excitation energy and load loss, and improve motor
Power Factor when the motor is running inefficiently at light loads.
100%
Efficiency
0
50%
Load
Figure 4.
Induction Motor Efficiency
100%
Copper Losses
Stray Losses
Losses
Magnetising
Losses
Friction Losses
Figure 5.
Induction Motor Losses
0
Suresense Technologies©
50%
Load
100%
Integra 2.2-630 kW Version 3.0
January 2014
9
INTEGRA PRODUCT SPECIFICATIONS
Parameter
Description
Supply Voltage
220 – 690V +6% / -15%
Supply Frequency
47/63 Hz
Ambient Temperature
-10 - +40C, Reduce kW (HP) Rating 2% per Deg C up to 50 C
Storage Temperature
-40 - +60 C
Relative Humidity
<95% No condensation allowed
Application Sets
7 Application sets are provided as standard
Altitude
Maximum 1000 M. Reduce kW Rating by 1% per additional
100 M
Starting Duty
2.5 X unit rating in amperes for 60 Sec, 3 X unit rating in
amperes for 30 Sec, 4 X unit rating in amperes for 10 Sec,
5.5 X unit rating in amperes for 5 Sec.
Starts per Hour
12 evenly spaced starts per hour at the ‘Starting Duty’ ratings
Pedestal Voltage
25 – 80% of supply voltage 1% increments
Starting Current Limit
25 – 80% of the DOL starting current in 1% increments
Starting Current Time
0 – 255 in 1 Sec increments
Starting Torque
6 – 64% of the DOL starting torque in 1% increments
Kick Start Level
9 – 100% of the DOL starting torque in 1% increments
Kick Start Time
0.1– 25 Sec in 0.1 Sec increments
Ramp Up Time
0.5 – 255 Sec in 1 Sec increments
Ramp Down Time
0.5 – 120 Sec in 1 Sec increments
Step Down Voltage
100 - 30% Line voltage in 1% increments
Fault Detection
Shut down for loss of phase and short-circuit Thyristor
Cooling
Naturally Cooled 2.2-22kW, Force Cooled 30kW+
Relays
Contact Rating 1.2KVA, 250V AC Max
Fan Voltage
110 or 220V as specified
Enclosure
IP20
Safety Standards
CE
Suresense Technologies©
Integra 2.2-630 kW Version 3.0
January 2014
10
POWERBOSS INTEGRA SELECTION GUIDE 2.2 TO 90KW
POWER RATING @ 220-480V
5.5 (7.5)
Natural
SI 7.5
5
15
4 (5)
7.5 (10)
Natural
SI 11
5
23
5.5 (7.5)
11 (15)
Natural
SI 15
5
30
7.5 (10)
15 (20)
Natural
SI 22
5
42
11 (15)
22 (30)
SI 30
10.2
53
15 (20)
30 (40)
Forced
SI 37
10.2
65
22 (30)
37 (50)
Forced
SI 55
10.2
97
30 (50)
55 (75)
Forced
Motor kW
(HP) @
Cooling
3 (4)
Protection
Motor kW
(HP) @
208-230V*
11
380/460V*
Motor Rating
Amps
IP20
SIZE 2
5
Weight kg
SIZE 1
H 385
W 130
D 227
SI 1/ SM
Model
220 - 480V
Chassis
Size
HxWxD mm
H 325
W 130
D 120
Natural
POWER RATING @ 525-690V
690V*
15 (20)
Natural
SI 11
5
15
15 (20)
22 (30)
Natural
SI 15
5
30
22 (30)
30 (40)
Natural
SI 22
5
42
30 (40)
37 (50)
SI 30
10.2
53
37 (50)
45 (60)
Forced
SI 37
10.2
65
45 (60)
75 (100)
Forced
SI 55
10.2
97
75 (100)
90 (125)
Forced
Motor kW
(HP) @
Cooling
Motor kW
(HP) @
575V*
11 (15)
Protection
Motor Rating
Amps
IP20
SIZE 2
11
Weight kg
SIZE 1
H 385
W 130
D 227
5
Model
525 - 690V
Chassis
Size
HxWxD mm
H 325
W 130
D 120
SI 7.5
Natural
* Units should be sized by motor current, the kW ratings are a guide only.
Suresense Technologies©
Integra 2.2-630 kW Version 3.0
January 2014
11
INTEGRA SELECTION GUIDE 75KW TO 630KW
SI 90
22
170
55 (75)
90 (125)
132 (180)
N/A
IP20
SI 110
24
205
63 (85)
110 (150)
150 (200)
N/A
IP20
SI 132
28
255
75 (100)
132 (180)
186 (250)
N/A
IP20
SI 150
28
290
85 (120)
150 (200)
220 (290)
300
(400)
IP20
SI 185
33
340
110 (150)
186 (250)
260 (350
N/A
IP20
SI 225
33
410
132 (180)
225 (300)
315 (420)
400
(550)
IP20
SI 260
46
475
150 (200)
260 (350
375 (500)
N/A
IP20
SI 315
46
580
186 (250)
315 (420)
450 (600)
550
(750)
IP20
SI 375
48
670
215 (300)
375 (500)
500 (650)
N/A
IP20
SI 450
72
800
260 (350)
450 (600)
600 (800)
800
(1100)
IP20
SI 630
110
1100
315 (420)
630 (850)
850 (1100)
1100
(1500)
IP20
Units should be sized by motor current; the kW ratings are a guide only.
Suresense Technologies©
Protection
IP20
690V
150
(200)
Motor kW
(HP) @
110 (150)
Motor kW
(HP) @
75 (100)
525/575V*
45 (60)
Motor kW
(HP) @
145
380/480V
22
Motor kW
(HP) @
SI 75
208-230V
Motor Rating
Amps
SIZE 6
Weight kg
SIZE 5
Please
contact
sales
office for
details
SIZE 4
H750
W480
D265
SIZE 3
H670
W380
D225
Model
Chassis
Size
HxWxD mm
H448
W305
D205
Integra 2.2-630 kW Version 3.0
January 2014
12
LOAD AND DUTY CYCLE TABLE
Application
Load Type
Inertia
Starts / Hour
Low
Low
12 or Less
13-18
Standard
Heavy
Positive Displacement
Pump
Medium
Low
12 or Less
13-18
Standard
Heavy
Submersible Pump
Medium
Low
8 or Less
9-15
Standard
Heavy
Reciprocating
Compressor
Medium
Medium
10 or Less
11-15
Standard
Heavy
Screw Compressor
Medium
Medium/High
8 or Less
9-15
Standard
Heavy
Axial Fan - No Load
Start
Low
High
4 or Less
5-8
Standard
Heavy
Axial Fan - Full Load
Start
Medium
High
3 or Less
4-6
Heavy
Very Heavy
Blower
Low
Low
4 or Less
5-8
Standard
Heavy
Centrifuge
Low
Very High
1
Conveyor Off Load Start
Low
High
10 or Less
11-15
Standard
Heavy
Conveyor On Load Start
High
High
6 or Less
7-10
Heavy
Very Heavy
Steel Press
Low
High
6 or Less
7-10
Standard
Heavy
Escalator
Low
High
6 or Less
7-10
Standard
Heavy
Plastic Extruder Off Load
Start
Low
Low
10 or Less
11-15
Standard
Heavy
Grinders
Low
High
6 or Less
7-10
Standard
Heavy
Circular Saw
Low
Low
10 or Less
11-15
Standard
Heavy
Centrifugal Pump
Suresense Technologies©
Start Type
Very Heavy
Integra 2.2-630 kW Version 3.0
January 2014
13
INTEGRA STARTING DUTY TABLE
Model
Motor Current
Rating
Standard
Motor Current
Rating
Heavy
Motor Current
Rating
Very Heavy
SI 1/SM
11
8
6
SI 7.5
15
10
7.5
SI 11
23
15
10
SI 15
30
19
15
SI 22
42
28
20
SI 30
53
38
28
SI 37
65
47
35
SI 55
97
68
50
SI 75
145
105
75
SI 90
170
120
97
SI 110
205
145
105
SI 132
255
170
120
SI 150
290
206
145
SI 186
340
255
170
SI 225
410
290
206
SI 260
475
340
255
SI 315
580
410
290
SI 375
670
475
340
SI 450
800
580
410
SI 630
1100
800
580
Suresense Technologies©
Integra 2.2-630 kW Version 3.0
January 2014
14
SIZING INTEGRA FOR A PARTICULAR DUTY
Determine the load type from the Load and Duty Cycle Table paying particular attention
to the starts per hour rating on page 12, and then select a Integra according to the
Motor Current from the Table on page 14.
Example;
Load Type - Reciprocating Compressor, 15 starts per hour
Start Type
=
Heavy
Motor Current =
145
Integra required is a SI 110.
If a particular application is not listed on page 13 refer to the Starting Duty and Starts per
Hour listed in the INTEGRA SI PRODUCT SPECIFICATIONS on page 9.
Suresense Technologies©
Integra 2.2-630 kW Version 3.0
January 2014
15
INSTALLATION
IMPORTANT SAFETY NOTICE
NOTICE IMPORTANTE DE SÉCURITÉ
SAFETY AT WORK
SÉCURITÉ AU TRAVAIL
The owner, installer and user of this Integra unit are responsible for its correct
installation and use, and must ensure that;
Le propriétaire, l'installateur et l'utilisateur de cet appareil Integra sont
responsables de la conformité de son installation et de son utilisation, et doivent
s’assurer que :
a)
Only qualified persons install the unit.
L’appareil soit installé par des personnes qualifiées.
b)
No adjustments should be made with the unit live.
Qu’aucun réglage ne soit effectué lorsque l’appareil est sous tension.
The installation complies with the information contained in this publication.
Que l’installation soit effectuée conformément aux instructions contenues
dans cette publication.
The operation and maintenance of the unit complies with the relevant
Codes of Practice, Regulations and Statutory Requirements.
c)
d)
Que l’utilisation et la maintenance de l’appareil s’effectuent en conformité
avec les règles en vigueur : code de déontologie, réglementation et
obligations légales.
e)
All units must be installed in accordance with the current National
Electrical Code.
Que tous les appareils soient installés en conformité avec les normes
électriques nationales en vigueur.
Mark Group Commercial Limited, or their agents do not assume any liability,
expressed or implied, for any consequences resulting from inappropriate,
negligent or incorrect installation, application, use or adjustment of the product or
circuit design, or from the mismatch of the unit to a motor.
Mark Group Commercial Ltd., ainsi que ses agents, déclinent toute responsabilité,
exprimée ou sous-entendue, quant aux conséquences résultant d’une installation
ou d’une utilisation inappropriée ou inadaptée, de négligences commises, de
modifications effectuées sur l’appareil ou le circuit, ou de la non-compatibilité
entre l’appareil et le moteur.
Suresense Technologies©
Integra 2.2-630 kW Version 3.0
January 2014
16
MANUFACTURERS DECLARATION OF CONFORMITY
DÉCLARATION DE CONFORMITÉ DU FABRICANT
This is to certify that the products described in this manual conform to the
requirements of the following standards in respect of the low voltage directive,
73/23/EEC.
Le fabricant certifie par la présente que les produits décrits dans ce manuel sont
en conformité avec les normes suivantes prévues par la directive de bas voltage,
73/23/EEC
This is to certify that the products described in this manual conform to the
requirements of the following standards in respect of the European EMC directive,
Le fabricant certifie par la présente que les produits décrits dans ce manuel sont
conformes aux normes suivantes prévues par la directive européenne EMC,
EN60947-4-2, EN55011, EN55022, EN61000-4-2, EN61000-4-5, EN61000-4-6,
EN61000-4-11
SIGNED
I. HAMBLY
JANUARY 2014
SURESENSE TECHNOLOGIES LTD
UNIT 3-4
STATION ROAD BUSINESS PARK
PERRANPORTH
CORNWALL
TR6 0LH
Suresense Technologies©
Integra 2.2-630 kW Version 3.0
January 2014
17
PRIOR TO INSTALLATION
IMPORTANT SAFETY NOTICE
UNITS MUST BE INSTALLED IN ACCORDANCE WITH THE
CURRENT NATIONAL ELECTRICAL CODE
NOTICE IMPORTANTE DE SÉCURITÉ
TOUS LES APPAREILS DOIVENT ÊTRE INSTALLÉS EN
CONFORMITÉ AVEC LES NORMES ELECTRIQUES NATIONALES
1.
Carefully remove the unit from the packaging and check that the parts supplied
identify with the delivery note and the purchase order. Check that the parts
supplied identify with the kW size of the motor.
2.
Check the Voltage and Current ratings of the unit correspond with the motor
name plate details.
3.
Check the Voltage rating of the cooling fans if fitted.
4.
Check that there are no loose parts or objects within the unit.
5.
Check sufficient space exists to correctly install the unit.
6.
Check you have sufficient tools to correctly install the unit.
MECHANICAL INSTALLATION
Unless the unit is fitted within a suitable enclosure the following should be avoided.
1.
Exposure to rain, spray or wet areas.
2.
Exposure to explosive and/or corrosive atmospheres.
3.
Atmospheres containing a high proportion of conductive dust.
4.
Extremes of temperature and/or humidity beyond published limits.
WALL MOUNTING
Fix the unit to a flat vertical surface using the mounting holes provided using adequately
sized mounting bolts. Please see page 74 for details.
Care should be taken to ensure the orientation of the unit is correct and a gap of 80mm
(100mm for SI 30 and above) is maintained above and below the Integra unit. This is to
ensure a safe exit path for the heat generated by the semiconductors within the unit.
MOUNTING INTEGRA WITHIN AN ENCLOSURE
If the unit has been purchased purely for the soft start features and optimisation is not
required, the unit can be bypassed using a contactor driven by the Top of Ramp relay
provided within the unit, negating any need to consider any cooling requirements.
Suresense Technologies©
Integra 2.2-630 kW Version 3.0
January 2014
18
COOLING INTEGRA WITHIN AN IP54 ENCLOSURE
If the optimisation feature is required the installer must ensure that the temperature
within the enclosure (Tenc) is kept below the maximum permitted for Integra, which is
normally 40 C, (see page 9). Care should be taken to include any other heat producing
equipment within the enclosure into the calculation.
The following formula should be used to calculate the minimum airflow through the
enclosure.
AF
=
W
Tenc - Tamb
AF
=
Required airflow in cubic metres per hour
W
=
Power dissipation within the enclosure
Tenc
=
Maximum enclosure ambient temperature
Tamb
=
Temperature of external air (Deg C)
The power dissipation figure for the individual models can be taken from the table on
page 20.
Perform the minimum airflow calculation using the power dissipation information
provided in the Integra Heat Dissipation Table; the resultant figure should then be used
to select a cooling fan from the Fan Selection Table on page 20.
Example;
Integra SI 75
AF
=
522
40 - 30
= 52.2 M3/Hr
Airflow requirement is 52.2 M3/Hr
Fan required is a Papst (or any other manufacturer) 8556N which has a rating of 57
M3/Hr.
Suresense Technologies©
Integra 2.2-630 kW Version 3.0
January 2014
19
MINIMUM ENCLOSURE SIZE FOR OPERATION IN AN IP55 ENCLOSURE
To preserve the full rating of Integra the internal enclosure temperature must be
maintained at 40 C or below. The thermal resistance (Rth) of the enclosure must
therefore be low enough to naturally disperse the heat generated by Integra through the
walls of the enclosure.
The minimum enclosure size can be calculated as follows;
Rth
= E-X
P
Where;
E
=
X
=
P
=
A
Enclosure maximum ambient temperature
External ambient temperature
Total power dissipation (Watts) +any other equipment within the
enclosure.
=K
Rth
Where;
A
=
K
=
Effective surface area
Constant of thermal resistance per square meter.
(A constant of 0.12 Deg C per Watt is common for most metal enclosures,
contact the manufacturer for a more precise figure.)
The thermal resistance of the enclosure is dependant on the total surface area adjacent
to free air. Therefore the back of a wall mounting enclosure cannot be taken into
consideration.
Example;
Integra SI 75 controller
Total power dissipated within the enclosure = 522 Watts (excluding any other
equipment). See page 18.
External ambient temperature = 25 C
Rth
= 40-25 = 0.028 Deg C per Watt
522
Proposed enclosure dimensions = 1200 x 1200 x 400mm
A = (1.2 X 1.2 X 2) + (1.2 X 0.4 X 2) + (1.2 X 0.4 X 2) = 4.8 Sq M
Minimum value for A = K = 0.12 = 4.2 Sq M
Rth 0.028
The effective area of the proposed enclosure is greater than the minimum required for
this application therefore can be used.
Suresense Technologies©
Integra 2.2-630 kW Version 3.0
January 2014
20
INTEGRA HEAT DISSIPATION TABLE
Model
Power Dissipation
in Watts @ FLC
Model
Power Dissipation
in Watts @ FLC
SI 1/SM
40*
SI 132
918*
SI 7.5
54*
SI 150
1044*
SI 11
82*
SI 186
1224*
SI 15
108*
SI 225
1476*
SI 22
150*
SI 260
1710*
SI 30
190*
SI 315
2088*
SI 37
235*
SI 375
2412*
SI 55
350*
SI 450
2880*
SI 75
522*
SI 630
3960*
*= WATT LOSS AT MOTOR FULL LOAD CURRENT
FAN SELECTION TABLE
PAPST Model No.
Fan Model
Fan Model
110V
220V
8506N
4600N
Air Flow
Air Flow
With Filter 50Hz
With Filter 60Hz
L/sec
CFM
M3Hr
L/sec
CFM
M3Hr
8556N
13
24
57
15
28
67
4650N
40
82
159
47
96
186
Suresense Technologies©
Integra 2.2-630 kW Version 3.0
January 2014
21
ELECTRICAL INSTALLATION
IMPORTANT SAFETY NOTICE
UNITS MUST BE INSTALLED IN ACCORDANCE WITH THE
CURRENT NATIONAL ELECTRICAL CODE
NOTICE IMPORTANTE DE SÉCURITÉ
TOUS LES APPAREILS DOIVENT ÊTRE INSTALLÉS EN
CONFORMITÉ AVEC LES NORMES ELECTRIQUES NATIONALES
LIGHTNING STRIKES / VERY HIGH VOLTAGE TRANSIENTS
In areas subject to frequent lightning strikes or other very high voltage transients, a
suitably rated Metal Oxide Varistor (MOV) should connect each input line to earth. The
Varistors should not be mounted within the Integra enclosure.
CONTROL VOLTAGE TRANSIENTS
Where the supply voltage to the Integra is thought to be subject to EMI a suitable line
filter with transient voltage suppression should be fitted on the control supply.
COIL SUPPRESSION
It is good practice for any AC relay or contactor coil either connected to the Integra or
sharing a common control supply to be fitted with a RC suppresser. DC coils should be
fitted with a suitable flywheel diode.
INPUT / OUTPUT CONTROL CONNECTIONS
To avoid ‘ pick up’ it is good practice to keep all control connections as short as possible
and to run them separately from the main motor cables. If this cannot be guaranteed an
interposing relay fitted with suitable suppression must be used, mounted as close to the
Integra as possible.
HARMONICS
Because motor starting currents are measured in multiples of full-load current, the
harmonic effect of Integra is at its greatest during the starting phase. However, provided
the Ramp Time is not excessive the effects can be ignored.
When a longer Ramp Time is necessary due to high inertia loads, most regulatory
authorities will accept the use of Soft Starting provided the starts per hour are not
excessive. With this concession almost all Integra installations will not need any
special considerations.
Integra will introduce odd harmonics (5th and higher) while the Optimising function is
active during normal running at periods of light load. Harmonic currents are related to the
line current, which is significantly less during optimisation than the motor full load or part
load current.
The effects, which are measured at the point of common coupling (PCC) will be
minimal except in unusual circumstances.
Harmonic test data for optimisers is available if local regulations need to be satisfied.
Suresense Technologies©
Integra 2.2-630 kW Version 3.0
January 2014
22
POINT OF COMMON COUPLING
The point of common coupling (PCC) is the point at which a consumer is connected to
other consumers on the Public Electricity Supply, generally consumers with less than a
300 kVA total load (720 amps@415V) will be connected to a transformer shared with
other consumers.
Consumers with higher power demands will normally be connected to the medium
voltage network by a dedicated transformer, in which case this medium voltage level will
be their PCC.
The levels of harmonic current and voltage at intermediate points in a consumer's own
network are solely at the discretion of the consumer.
Example - If a factory is fed by a dedicated distribution transformer with a nominal ratio
of 11kV/415V and no other consumers are fed by the 415V system, then the PCC is at
11kV.
INDIVIDUAL MOTOR POWER FACTOR CORRECTION CAPACITORS
Power factor correction capacitors, if fitted to the motor, should be connected to the live
side of K1 (see mains connection drawings) and switched in or out before starting.
Never connect Power Factor Correction Capacitors to the output terminals of the Integra
unit.
THERMAL PROTECTION SWITCH
The thermal protection switch (if fitted) is the automatic reset type and should be wired
into the control circuit in such a way as not to allow an automatic re-start in the event of
a trip.
ADDITIONAL EQUIPMENT
All necessary electrical connections for mains, earth and control wiring are provided for
in the Integra unit. However the following additional components will need to be provided
in a new installation.
Isolator, Motor rated cable protection fuses, AC3 rated contactor and Motor Overload.
WARNING
INTEGRA USES THYRISTOR SWITCHING DEVICES IN ITS MAIN CIRCUIT AND IS
NOT DESIGNED FOR ISOLATION. A SUITABLY RATED MECHANICAL ISOLATION
METHOD MUST BE EMPLOYED IN LINE WITH THE MAIN INPUT TERMINALS TO
THE UNIT.
ATTENTION
INTEGRA UTILISE DES INTERRUPTEURS THYRISTOR DANS SON CIRCUIT
PRINCIPAL ET N'EST PAS DESTINÉ A L’ISOLATION. UNE ISOLATION
MÉCHANIQUE, QUI SOIT FIABLE ET COMPATIBLE AVEC LE SYSTÈME
D’ALIMENTATION DE L’APPAREIL, DOIT ÊTRE UTILISÉE
Suresense Technologies©
Integra 2.2-630 kW Version 3.0
January 2014
23
PROTECTIVE EARTH (ELECTRICAL GROUND)
IMPORTANT SAFETY NOTICE
UNITS MUST BE INSTALLED IN ACCORDANCE WITH THE
CURRENT NATIONAL ELECTRICAL CODE
NOTICE IMPORTANTE DE SÉCURITÉ
TOUS LES APPAREILS DOIVENT ÊTRE INSTALLÉS EN
CONFORMITÉ AVEC LES NORMES ELECTRIQUES NATIONALES
WARNING
THIS EQUIPMENT MUST BE EARTHED. CONNECT THE EARTHING STUD WITHIN
THE UNIT TO A SUITABLE LOW IMPEDANCE EARTH AS IS REQUIRED BY
STATUTORY REGULATIONS COVERING THE INSTALLATION OF ELECTRICAL
EQUIPMENT.
ATTENTION
CONNECTEZ LA FICHE DE TERRE INTÉGRÉE À L’APPAREIL À UNE PRISE DE
TERRE DE BASSE IMPÉDANCE AINSI QUE LE PRÉVOIT LA RÉGLEMENTATION
POUR L'INSTALLATION D’ÉQUIPEMENTS ÉLECTRIQUES
FUSE PROTECTION
The mains supply, and the control supply each require fuse protection. The installer
should always fuse the mains supply with motor rated fuses before the input to the unit.
Some retrofit installations may only be fitted with standard fuses, it is advisable to
replace these fuses with the motor rated type to avoid spurious failures.
`
Semiconductor fuses are available as an optional extra and must be mounted externally
on models SI 55 and below and Internally on models SI 75 and above.
WARNING
SEMICONDUCTOR FUSES SHOULD NOT BE USED IN PLACE OF CABLE
PROTECTION FUSES.
ATTENTION
NE PAS UTILISER DE FUSIBLES POUR SEMI-CONDUCTEURS À LA PLACE DE
FUSIBLES PROTEGEANT LES CÂBLES.
USE COPPER CONDUCTORS ONLY
N’UTILISEZ QUE DES CONDUCTEURS EN CUIVRE
POWER TERMINAL TORQUE SETTING
SI 1/SM to SI 55 Motor, Power and Earth terminals torque to 35lb/in (4Nm) torque.
SI 75 to SI-375 Motor, Power and Earth terminals torque to 150lb/in (17Nm) torque.
SI 450 to SI-630 Motor, Power and Earth terminals torque to 250lb/in (28Nm) torque.
Suresense Technologies©
Integra 2.2-630 kW Version 3.0
January 2014
24
INTEGRA POWER CONNECTIONS - DOL STARTER
From Fused
3 Phase Supply
K1
K2
Line
Contactor
Optional Reversing
Contactor.
Motor
Overload
Semiconductor
Fuses (if fitted).
L1
L2
L3
Integra
U
V
W
EARTH
EARTH
(Electrical
Ground)
U1-W2
Induction
Motor
V1-U2
Suresense Technologies©
W1-V2
Integra 2.2-630 kW Version 3.0
January 2014
25
STANDARD CONTROL CIRCUIT REQUIREMENTS – DOL STARTER
110/220V
Control Supply
FAN
(if fitted)
1
2
3
STOP
TB2
RL1
START
SOFT STOP
(If Required)
TB3
See
OVERLOAD
TT
K1
1
2
3
RL2
1
2
3
4
5
6
7
8
TB1
See
Note.
Relay RL1 closes when Integra is asked to start and maintains the line
contactor K1 after the start button is released. In the event of a fault Relay
RL1 will de-energise and drop out the line contactor.
WARNING
THE THERMAL PROTECTION SWITCH, TT (IF FITTED) IS THE
AUTOMATIC RESET TYPE. IF IT IS USED ELSWHERE IN THE CIRCUIT IT
SHOULD BE WIRED TO PREVENT THE UNIT FROM AUTOMATICALLY
RE-STARTING IN THE EVENT OF AN OVER TEMPERATURE TRIP.
TERMINALS 1 & 2 ON TB1 SHOULD BE LINKED IF TT NOT FITTED.
ATTENTION
L’INTERRUPTEUR THERMIQUE, TT (S’IL EST MONTÉ) SE REMET
AUTOMATIQUEMENT À ZÉRO. S’IL EST UTILISÉ AILLEURS DANS LE CIRCUIT,
IL DOIT ÊTRE CÂBLÉ AFIN QUE L’APPAREIL NE REDÉMARRE PAS
AUTOMATIQUEMENT DANS LE CAS D’UNE SURCHARGE THERMIQUE. LES
TERMINAUX 1 & 2 DOIVENT ETRE CONNECTES SI LA LIAISON A LA TERRE TT
N’EST PAS MONTEE.
Suresense Technologies©
Integra 2.2-630 kW Version 3.0
January 2014
26
CONTROL CIRCUIT REQUIREMENTS FOR REVERSING
110V/230V
Control Supply
FAN
(if fitted)
STOP
OVERLOAD
1
2
3
R1
TB2
RL1
REV
FOR
1
2
3
TB3
K2
See
K1
TT
K1
K2
R1
1
2
3
4
5
6
7
8
TB1
RL2
Integra
See
Note.
Relay RL1 closes when Integra is asked to start and maintains the direction
contactor K1 or K2 after the forward or reverse is released. In the event of a
fault Relay R1 will de-energise and drop out the direction contactor.
TT is the thermal trip fitted on the heatsink (if fitted).
WARNING
THE THERMAL PROTECTION SWITCH, TT (IF FITTED) IS THE
AUTOMATIC RESET TYPE. IF IT IS USED ELSWHERE IN THE CIRCUIT IT
SHOULD BE WIRED TO PREVENT THE UNIT FROM AUTOMATICALLY
RE-STARTING IN THE EVENT OF AN OVER TEMPERATURE TRIP.
TERMINALS 1 & 2 ON TB1 SHOULD BE LINKED IF TT NOT FITTED.
ATTENTION
L’INTERRUPTEUR THERMIQUE, TT (S’IL EST MONTÉ) SE REMET
AUTOMATIQUEMENT À ZÉRO. S’IL EST UTILISÉ AILLEURS DANS LE CIRCUIT,
IL DOIT ÊTRE CÂBLÉ AFIN QUE L’APPAREIL NE REDÉMARRE PAS
AUTOMATIQUEMENT DANS LE CAS D’UNE SURCHARGE THERMIQUE. LES
TERMINAUX 1 & 2 DOIVENT ETRE CONNECTES SI LA LIAISON A LA TERRE TT
N’EST PAS MONTEE.
Suresense Technologies©
Integra 2.2-630 kW Version 3.0
January 2014
27
STAR (WYE) DELTA INSTALLATION - DESCRIPTION OF OPERATION
MAINS CIRCUIT
The Integra should be connected as shown in the installation manual and operates as
follows.
When the motor is started using the existing start/stop circuit, the Star (Wye) contactor
K2 and the line contactor K1 are energised, at this stage no current should flow through
the motor. The Star (Wye) timer must be reduced to its minimum setting.
After the Star (Wye) timer operation is completed the Star (Wye) contactor K2 will deenergise and the delta contactor K3 will energise, the motor will then start according to
the settings.
CONTROL CIRCUIT
There are no control circuit connections other than the start circuit connection to terminal
block TB1.
INSTALLING ON A COMPRESSOR
Some Compressor control circuits require that the Compressor rotate within a
certain time frame dictated by the control software within the Compressor. More
often than not, the lack of rotation before the delta contactor is energised will
cause the Compressor safety circuit to trip due to lack of oil pressure.
If this is the case you need to configure the motor to start in delta. To do this follow the
instructions below.
1.
Remove the output from the ‘Compressor Controller’ to the Star (Wye) contactor
coil.
2.
Connect the output from the ‘Compressor Controller’ to the delta contactor coil
and the line contactor coil together, this will ensure the Compressor begins to
rotate as soon as the Integra is started.
The control connections to the Integra should not be changed. See page 28 for
connection drawing.
Suresense Technologies©
Integra 2.2-630 kW Version 3.0
January 2014
28
INSTALLING INTEGRA WITH AN EXISTING STAR (WYE) DELTA STARTER
3 Phase Supply
Isolator
Note
TT is the connection for the N/C thermal
trip fitted to all units covered in this
manual.
TT
K3
Fan
Voltage
110 or
230VAC
L1
L2
L3
1 2 3 4 5 6 7 8
TB1
Integra
FAN
(if fitted)
U
V
W
Earth
K1
K3
K2
Line
Motor
Overload
U1 V1
W2
U2
Suresense Technologies©
Earth
(Electrical
Ground)
W1
V2
Star (Wye)-Delta Timer
must be set to Minimum
Time
Integra 2.2-630 kW Version 3.0
January 2014
29
The Start Command TB1; Terminal block 1 terminals 1 and 2 are the start command
terminals. Important this is a dry contact meaning no voltage must be inserted into
these contacts. The Integra unit will do nothing unless the start command is closed, this
is either via a wire link or a signal from a N/O dry contact on a contactor/ PLC. If for
instance there is a contactor on the output of the Integra unit, an auxiliary contact is
always fed back to the start command telling the Integra unit when the contactor has
been closed and it is ok to start the motor.
TIP: If a constant fault appears when powering up the unit on first installation this
usually indicates a contactor on the output of the unit is open and a start command has
been giving via a link in the start command terminals. The Integra attempts a start but
flags a fault because it cannot see a motor because of the open contactor. Solution
feed a start command from a N/O on the contactor to the Integra unit.
Interacting with a Star / Delta
The most common method besides DOL (direct on line) for starting a motor is Star / Delta,
It is not usually viable to pull out the Star / Delta so the most practical solution is to create a
connection which interact with the Star / Delta starter.
.
 The Integra unit is installed above where
the delta and Line contactors link. The
Integra unit feeds the Star / Delta.
 The Start Command is wired from a N/O
on the delta contactor to terminals 1 and
2 on TB1.
 The Star / Delta timer is turned down if
possible.
 When the start button is pushed the star
and line contactors come in first but the
motor does not turn.
 The Star contactor drops out almost
immediately and the Delta contactor
pulls in.
 The Integra unit gets a Start Command
from the delta contactor.
 The Integra unit soft starts the motor in
delta.
Important: Star/Delta connections must always be done in this way NO exceptions. Do not connect the
start to the line contactor this will damage the Integra unit.
Suresense Technologies©
Integra 2.2-630 kW Version 3.0
January 2014
30
INSTALLING INTEGRA ON TWO SPEED TWO WINDING MOTORS
GENERAL
The principle of the two speed induction motor and its torque/speed characteristics are
the same as the standard squirrel cage motor except that the stator is fitted with two
electrically separate windings. As the windings are electrically separate any speed
combinations are possible, commonly the motors are 2 pole (2850rpm) and 4 pole
(1450rpm).
Other two speed motors have tap (or Dhalander) wound single winding stators, to
change the speed the windings are re-configured by contactor control gear similar to two
winding motors. Contact or the local distributor for Dhalander connection options.
MAIN CONNECTIONS
Integra must be connected after the switch fuse and motor overload but before the stator
control gear. Some motors may be fitted with an overload for both windings; in this case
the overloads will be fitted after the individual contactors.
In most cases the stator control gear will be mechanically as well as electrically
interlocked.
CONTROL CONNECTIONS
To select the Slow Speed Winding, close the Slow speed start contact, contactor K1
will energise and close the start circuit on TB1. Provided there is no fault with either the
incoming supply or Relay RL2 will remain energised and maintain contactor K1 via
terminal block TB3.
Integra will then start the motor in the normal manner.
To select the Fast Speed Winding, close the Fast speed start contact, contactor K2 will
energise and close the start circuit on TB1. Provided there is no fault with either the
incoming supply or Relay RL2 will remain energised and maintain contactor K2, via
terminal block TB3.
Integra will then start the motor in the normal manner.
See pages 30 and 31 for drawings.
Suresense Technologies©
Integra 2.2-630 kW Version 3.0
January 2014
31
MAINS CONNECTIONS FOR TWO SPEED TWO WINDING MOTOR
3 Phase Supply
Switched and Fused
Motor Overload
Semiconductor Fuses
(If Fitted)
L1
L2
L3
INTEGRA
FAN
(If Fitted)
U
V
W
K1
K2
U2
Suresense Technologies©
Earth
U1
V2
V1
W2
W1
Integra 2.2-630 kW Version 3.0
January 2014
32
CONTROL CONNECTIONS FOR TWO SPEED TWO WINDING MOTOR
110V/230V
Control Supply
FAN
(if fitted)
STOP
1
2
3
OVERLOAD
TB2
RL1
1
2
3
`
TB3
K1
K1
K1
RL2
K2
FAST
SLOW
See
K2
TT
1
2
3
4
5
6
7
8
TB1
See
Integra
Note.
Relay RL2 is configured as a fault relay as standard. RL2 closes when power is
applied and opens in the event of a fault de-energising the slow or fast speed
contactors.
WARNING
THE THERMAL PROTECTION SWITCH, TT (IF FITTED) IS THE
AUTOMATIC RESET TYPE. IF IT IS USED ELSWHERE IN THE CIRCUIT IT
SHOULD BE WIRED TO PREVENT THE UNIT FROM AUTOMATICALLY
RE-STARTING IN THE EVENT OF AN OVER TEMPERATURE TRIP.
TERMINALS 1 & 2 ON TB1 SHOULD BE LINKED IF TT NOT FITTED.
ATTENTION
L’INTERRUPTEUR THERMIQUE, TT (S’IL EST MONTÉ) SE REMET
AUTOMATIQUEMENT À ZÉRO. S’IL EST UTILISÉ AILLEURS DANS LE CIRCUIT,
IL DOIT ÊTRE CÂBLÉ AFIN QUE L’APPAREIL NE REDÉMARRE PAS
AUTOMATIQUEMENT DANS LE CAS D’UNE SURCHARGE THERMIQUE. LES
TERMINAUX 1 & 2 DOIVENT ETRE CONNECTES SI LA LIAISON A LA TERRE TT
N’EST PAS MONTEE.
Suresense Technologies©
Integra 2.2-630 kW Version 3.0
January 2014
33
DESCRIPTION OF USER CONTROL SETTINGS
MAINS SUPPLY VOLTAGE SELECTION
WARNING
IN ORDER TO POWER THE PCB FROM DIFFERENT MAINS VOLTAGES THE PCB
MOUNTED TRANSFORMER MUST BE CONFIGURED AS SHOWN BELOW TO SUIT
THE APPLIED VOLTAGE. SEE THE SUPPLY VOLTAGE SELECTION DIAGRAM
BELOW.
ATTENTION
AFIN D'ADAPTER L’ALIMENTATION DU PCB À LA TENSION DU SECTEUR, LE
TRANSFORMATEUR RELIÉ AU PCB DOIT ÊTRE CONFIGURÉ COMME INDIQUE
AU DESSOUS EN FONCTION DE LA TENSION UTILISÉE. VOIR LE DIAGRAMME
DE SELECTION DE LA TENSION D’ALIMENTATION CI-DESSOUS.
TB1
TB2
TB3
1 2 3 4 5 6 7 8
1 2 3
1 2 3
LCD
Display
Voltage
Selection
Link*
1
3
C
2
TB5
K2 G2 G1 K1
TB6
K4 G4 G3 K3
TB7
K6 G6 G5 K5
Units rated at 220V link terminal C to terminal 1
Units rated at 380 to 415V link terminal C to terminal 2
Units rated at 440 to 480V link terminal C to terminal 3
Units rated at 525 to 575V link terminal C to terminal 3
Units rated at 690V link terminal C to terminal 3
WARNING
Units must be factory supplied for the correct voltage.
Suresense Technologies©
Integra 2.2-630 kW Version 3.0
January 2014
34
Accessing the Integra Menu
There are two methods of accessing the menu system, which method will depend on whether or not there
is a start command on TB1 1 and 2 (wire link). To prevent the Integra from starting the motor up the wire
link can either be removed or the unit can be powered up holding the ESC key. If there is no link the unit
will display ‘Awaiting Start’, ‘Press ESC for menu’.
The Key Pad
Awaiting Start
Press ESC for Menu
The Up And Down Keys are used to move up
and down the menu tree. Please also refer to
the ‘SI Menu Tree’ document for a full view of
the menu system.
The Up and Down keys also change the value
of the parameters.
The Esc and Enter Keys are used
to Move back and forth through the
Menu sections. They are also used
to answer ‘Yes’ or ‘No’ questions
There are two menus available the menu that is accessed will depend on the password
inputted.
User menu:
Main menu:
User Menu vs. Main Menu
The Integra unit can be set up using the user menu alone but there is limited
capability when it comes to energy saving parameter adjustment, there are two
response options High or Normal. If more adjustability is needed then a third option
which is the default can be used; custom response. Integra when in custom
response mode will use the main menu parameters, the setup in this case is also
simple and an application set can be chosen from the Application set Menu. This will
load in the appropriate energy saving parameters for the chosen application.
Suresense Technologies©
Integra 2.2-630 kW Version 3.0
January 2014
User Menu
User Menu
Ramp Up Time (s)
User Menu
Pedestal Voltage (%)
Voltage (100%)
Start Delay this parameter creates a delay in the Integra starting process, it
can be used for example in the case where there is a contactor installed
between the Integra and the motor, when the contactor closes there may be a
bit of bounce on the contacts which could be interpreted as a fault within the
motor, so a simple delay is added which allows the external gear to settle. It
can also be used in a scenario where the process has to perform another job
before the motor is allowed to start but the start process is issues all at the
same time and the Integra needs to wait 20s before beginning the internal
checks and process to start the motor.
Ramp up Time is the time taken for the Integra unit to ramp the
voltage from the pedestal voltage to the maximum voltage, the
basic principle is; the longer the ramp the lower the peak of
current and initial torque applied to the motor and application.
This gives benefits both electrically and mechanically. Parameter
range is 0 - 255
Pedestal Voltage is the initial voltage applied to the motor at the
start, the pedestal voltage is set between 30 - 70%. If the motor
shaft does not start turning within 3 – 5 sec then this generally
means the pedestal is not high enough and it should be
increased.
Pedestal Voltage
User Menu
Start Delay (s)
35
Time (s)
User Menu
Energy Saving On/Off
User Menu
Load Response
Energy Saving On/Off this software switch is used to turn the
energy savings On or Off and is changed by pushing the Enter key.
TIP: The ESC key can be used to turn the energy saving on and off
whilst the motor is running regardless of the setting on this switch
but when the Integra unit restarts it will look at this switch and
proceed accordingly.
Load Response this software switch has three options; Normal,
High and Custom. The normal setting is generally used for
applications such as; Escalators, Conveyor belts and Pump Jacks.
The high response is used for applications such as Injection
Moulding, Hydraulic packs and rock crushers. If more control is
required then the Main Menu must be used and this switch left on
custom.
Important Parameters must be saved after adjustment, this
is not done automatically.
User Menu
Ramp Down (s)
Ramp Down is the opposite of the ramp up and is only used on water pumps to
reduce water hammer. The motor is ramped down reducing the energy caused
by the water pressure, water hammer can cause serious damage to pipes and
valves.
Suresense Technologies©
Integra 2.2-630 kW Version 3.0
January 2014
36
User Menu
Step Down (s)
User Menu
Relay 1 Function
Relays a run relay only energizes when the motor is running, if there is a fault or a
stop command this relay will be de-energized. A TOR or top of ramp relay energizes
when the output of the Integra reaches full voltage after the ramp up. The relays can
also be programmed to energize or de energize on a fault.
User Menu
Relay 2 Function
Return to Awaiting start this option is used when adjustments to parameters have been
made and need to be saved or the option can be used simply to exit the menu system.
The procedure for adjusting a parameter and saving the data is outlined in the next
section.
Return to
Awaiting Start
Line Voltage %
100
80
65
50
Motor
Running
D
B
E
A
C
30
38
0
Time in Seconds
A = Pedestal
B = Ramp
C = Ramp Down
D = Step down (only for water pumps)
E = Energysavings
Suresense Technologies©
15
Integra 2.2-630 kW Version 3.0
January 2014
37
Procedure for Adjusting and saving a parameter
This example shows how to change the ramp up from 25 sec to 30 sec
User Menu
Start Delay (s)
User Menu
Ramp Up Time (s)
X5
Ramp Up Time (s)
30 s
Ramp Up Time (s)
25 s
User Menu
Ramp Up Time (s)
Return to
Awaiting Start
Awaiting Start
Press ESC for menu
Creating Data Mirror
TIP: If ‘Creating Data mirror’ does not come up then the parameters have not been saved.
Suresense Technologies©
Integra 2.2-630 kW Version 3.0
January 2014
38
Main Menu
The main menu gives full access to all areas of the Integra unit, the special soft start features
such as the current limit can be used and also any of the intelligent control options can be setup
to maximize the saving by switching the motor off when it is not needed. On the other hand the
main menu can be used to access the application sets to quickly setup the Integra unit but also
allowing for more flexibility if needed either at the time of installation or later on.
Quick Set up procedure in Main Menu
Application Sets
Quick Start
Application Sets
Injection Moulding
When an application set is chosen all the parameters for the soft
start and energy saving are automatically loaded in. The motor
can then be started, if for any reason though the commissioning
process it is decided that the motor may be starting too quickly
or too slowly, then the appropriate parameters can be adjusted
in this case ramp up time and pedestal voltage.
The application sets are designed to work first time.
Tip: If there is ever doubt as to which application set to use,
quick start should be chosen.
Application Sets
Injection Moulding 2
Application Sets
Mechanical Press
Application Sets
Escalator
Suresense Technologies©
Integra 2.2-630 kW Version 3.0
January 2014
Application Sets
Compressor
Application Sets
Oil Well 1
Application Sets
Oil Well 2
Application Sets
Oil Well 3
Application Sets
Water Pump
Application Sets
Rock Crusher
Suresense Technologies©
39
Integra 2.2-630 kW Version 3.0
January 2014
40
Main Menu
Parameter Menu
Parameter Menu
Application Sets
Application Sets
Quick Start
Application Sets
Injection molding
Application Set
Updated….
Main Menu
Parameter Menu
Return to
Awaiting Start
Suresense Technologies©
Save Changes?
Enter: Yes ESC: No
Integra 2.2-630 kW Version 3.0
January 2014
41
APPLICATION SETS - DEFAULT PARAMETER TABLE
After selecting a Standard Application each of the individual parameters within the
application can be changed as required using the Extended Soft Start Parameters.
The supply frequency setting on Input 3 must be set to suit the site requirements,
see page 63 for details.
The default level is 50Hz.
Optimum
Efficiency
Energy Ramp
Down
Stall
Compensation
8
55
ON
N
0
N/A
80
79
5
20
2
10
Injection
Moulding
8
50
ON
N
0
N/A
65
76
5
20
2
10
Injection
Moulding 2
8
50
ON
N
0
N/A
50
76
5
8
3
10
Mechanical
Press
10
55
ON
N
0
N/A
50
79
8
20
2
10
Escalator
8
50
ON
N
0
N/A
50
79
8
20
2
10
Compressor
5
60
ON
N
0
N/A
50
79
8
20
2
15
Oil Well
Pump 1
5
60
ON
N
0
N/A
55
79
8
8
2
10
Oil Well
Pump 2
8
55
ON
N
0
N/A
50
79
8
8
2
10
Oil Well
Pump 3
8
50
ON
N
0
N/A
48
79
8
8
2
10
Water Pump
10
50
OFF
N
10
N/A
48
79
20
20
1
8
Rock
Crusher
10
65
ON
N
0
DOL
50
79
5
150
3
20
Suresense Technologies©
Dwell Time
Voltage Limit %
Energy Ramp Up
Input 2
Ramp Down Time
(s)
Energy Saving
On/Off
Quick Start
Load Response
Pedestal Voltage
%
Ramp Up Time (s)
Application
Sets
Integra 2.2-630 kW Version 3.0
January 2014
42
ROCK CRUSHER
Start 1
Start 2
100
Line Voltage %
65
Optimisation
Optimisation
Dwell
Time
Dwell
Time
Ramp
10
20
Time in Seconds
0
10
If the above application is selected a DOL start can be selected (Start 2) by bridging
terminals 3 and 4 on Terminal Block TB1. This feature is useful should a full toque start
be required if the Crusher must be started when loaded.
SLIP RING MOTOR APPLICATIONS
With Slip Ring Motor Applications the rotor starter provides the acceleration torque for
the driven load. In no circumstances should the rotor starter be bypassed or modified.
Integra should be installed in the stator circuit as per cage motor applications; we
recommend the following settings as a starting point.
Pedestal Voltage
80%
Ramp Time
5 seconds
Dwell Time
60 Seconds
Suresense Technologies©
Integra 2.2-630 kW Version 3.0
January 2014
43
PARAMETER MENU EXTENDED SOFT START
CURRENT LIMIT LEVEL AND TIME
Extended Software
Current Limit Time (s)
The Current Limit feature can be useful when a ceiling is placed on the current that can be drawn from the supply, by the
supply authority. Typical use of the current limit feature would be to start a large, unloaded axial fan with the minimum current
possible.
Integra starts the motor at the Pedestal Voltage which acts as the Current Limit level (B) and will hold the current for the
programmed time limit (C). On reaching full speed the motor current would drop to near normal, at this point it can be seen
that the Ramp Up continues with the voltage ramp to full voltage.
The Current Limit Time is adjustable in increments of 1 second, between 0 and 255 seconds. If high starting currents are
expected for longer periods of time a larger Integra may need to be fitted. See Integra manual for starting current ratings.
KICK-START LEVEL AND TIME
Extended Software
Kick Start Level (%)
The Kick-Start feature (D) can be useful on high static friction loads such as a slurry pump and is used to break the
static friction between the material and the motor.
In general the Kick-Start feature should not be used on any other type of load.
DOL Current %
Line Voltage %
Extended Software
Kick Start Time (s)
10
08
0
6
5
D
Ramp to
Full
Voltage
B
C
Optimisation
2
5
3
10
0Time in Seconds 0
PLUG BRAKING (REVERSE TORQUE BRAKING)
Extended Software
Plug Breaking Level (%)
This feature enables Integra to provide a soft start in the forward direction and Plug Braking in the reverse
direction to provide braking torque to the driven load.
This feature can be used to safely provide a controlled stop for applications such as a Circular Saw or
Band Saw.
Forward
Braking
64
C
Braking Torque
65
50
40
%
Time
D
100
80
Contactors
Reverse
Line Voltage %
Extended Software
Plug Breaking Time (s)
Optimise
6
Time in Seconds
BRAKING TORQUE LEVEL AND TIME - PLUG BRAKING
When the stop signal is given Integra will then de-energise the forward contactor (K1) and select the reverse direction (braking) contactor (K2). Integra
will then inject the set amount of Braking Torque for the set amount of time, after which Integra will turn off the Thyristors, de-energise the reverse
contactor and be ready for another start.
The Braking Torque Level (C) is adjustable in increments of 1%, between 6% and 64% of the direct on line (DOL) starting torque.
The Braking Torque Time (D) is adjustable in increments of 1 second, between 0 and 255 seconds. If high braking currents are expected for longer
periods of time a larger Integra may need to be fitted. Contact Suresense Technologies for further details.
ZERO SPEED DETECTION - PLUG BRAKING
When accurate sensing of zero speed is required, as opposed to simply using the Braking Torque Time, a normally closed contact from a proximity
detector or similar can be connected into Input 2 on terminals 3 and 4 of terminal block TB1. When zero speed is detected the contact would then open
forcing Integra to turn off the Thyristors, de-energise the reverse contactor irrespective of the programmed braking time.
Input 2 must be configured as Plug Braking Sensor.
Suresense Technologies©
Integra 2.2-630 kW Version 3.0
January 2014
44
Extended Software
DC Breaking level (%)
Extended Software
DC Breaking time (%)
Extended Software
Phase Rotation For/Rev
Extended Software
Dual Ramp
Suresense Technologies©
Currently Unavailable
Integra 2.2-630 kW Version 3.0
January 2014
45
Manual adjustments to Energy Saving Parameters
Voltage limit, this limits how far back the Integra can take the voltage, there is a balance
between the Integra acting fast enough to heavy load changes and the motor slowing down,
if the Integra was allowed to take the voltage back as far as it wanted there would be a point
where the motor would start slowing down and the stall compensation would kick in, this
would cause an unstable system and oscillations.
The Voltage limit however also has an impact on savings, it is recommended not to go less
than 46%. In general the lower this number on a fully varying load system such as an
escalator the higher the saving potential.
Stall Compensation, this parameter adds blocks of voltage very quickly and is activated by
the magnetic slip detection circuit. If the software algorithm sees a change in the motor shaft
speed and the trend is going towards a heavy load condition, extra voltage is added which in
turn creates more torque within the motor, this parameter should usually be set between 1
and 3. One being a slower reacting load (conveyor) and 3 being a very fast acting load
(injection molding machine with accumulators).
Note: The applications sets will set these parameters when selected.
Frequency selection
The Integra unit must either be set for 50 or 60 Hz, this is selected on input 3 which are
terminals 5 and 6 on TB1. If the wrong frequency is selected the unit will flag up a fault.
Current Limit
There is another parameter which can be quite useful in the Main Menu Extended Soft start,
called Current limit. The current limit parameter holds the voltage at the pedestal voltage for
a set period of time defined in the current limit parameter. This has the effect of capping the
current, this is especially useful on high inertia loads where a steady voltage is applied to the
motor and the motor is allowed to slowly accelerate to synchronous speed.
Suresense Technologies©
Integra 2.2-630 kW Version 3.0
January 2014
46
Information displayed on the Integra LCD when the motor is running
The screen below represents normal working conditions, the information can vary if one of the
energy saving applications is active.
Motor Efficiency
Energy Saving on or
Off
ES: On
M EFF: 56%
C ANGLE: 38
Conduction Angle will track the changes in loading on the motor and represents
the constant change in output of the Integra. If the conduction angle was 2 this
means full output anything else is a varied output according to the load at a
given point. This is also used to set up intelligent control applications, please
refer to the SI Intelligent Control Applications document.
Suresense Technologies©
Integra 2.2-630 kW Version 3.0
January 2014
47
POWER CONNECTIONS FOR PLUG BRAKING (REVERSE TORQUE
3 Phase Supply
Switched and Fused
Motor Overload
Semiconductor Fuses
(If Fitted)
L1
L2
L3
INTEGRA
FAN
(If Fitted)
U
V
W
K1
K2
U
Suresense Technologies©
Earth
V
W
Integra 2.2-630 kW Version 3.0
January 2014
48
CONTROL CONNECTIONS FOR PLUG BRAKING (REVERSE TORQUE BRAKING)
110V/230V Control
Supply
FAN
(if fitted)
1
2
3
STOP
TB2
RL1
START
1
2
3
Brake
OVERLOAD
K1
K2
K1
Forward
Brake
TB3
K1
*
See
1
2
3
4
5
6
7
8
TB1
See
Note
* = Normally closed contact from optional speed sensing relay.
Suresense Technologies©
RL2
Integra
Integra 2.2-630 kW Version 3.0
January 2014
49
PARAMETER MENU ENERGY SAVING MENU
VOLTAGE LIMIT
Energy Saving Menu
Voltage Limit
Sets the minimum voltage Integra will supply the motor during optimisation.
The Minimum Voltage Level is adjustable between 25 and 100% of the line voltage in 1%
increments. The default level of 46 is suitable for most applications.
OPTIMUM EFFICIENCY
Energy Saving Menu
Optimum Efficiency
The Optimum Efficiency Setting is an operating area around the target motor efficiency which is
calculated by the Integra software.
Adjusting this parameter changes the frequency of voltage steps (torque) to the motor per load change
therefore increasing the torque of the motor in response to a given load change.
Adjusting the setting to high (82%+) may restrict the output voltage of Integra at full motor load, adjusting
the setting to low (65%) may force Integra from Optimisation to full voltage to soon, restricting savings
The recommended setting is between 76% and 82% depending on load type.
See PG 50
for details
Energy Saving Menu
Dead Band (-)
The default setting of 79% is sufficient for most applications.
Motor efficiency %
Energy Saving Menu
Dead Band (+)
The Optimum Efficiency setting is adjustable between 49 and 96% in 1% increments.
82
Target
Motor
Efficiency
74
ENERGY RAMP UP
Energy Saving Menu
Energy Ramp Up
Energy Ramp Up is the time taken to increase the voltage to the required level during Optimisation.
Settable between 1 and 255 seconds in 0.01 second increments.
The default level of 20 is sufficient for most applications.
ENERGY RAMP DOWN
Energy Saving Menu
Energy Ramp Down
Energy Ramp Down is the time taken to decrease the voltage to the required level during Optimisation.
Settable between 0.01 and 2.55 seconds in 0.01 second increments.
The default level of 20 is sufficient for most applications.
Suresense Technologies©
Integra 2.2-630 kW Version 3.0
January 2014
50
Energy Saving Menu
Slip Tolerance
See PG51 for more details
Energy Saving Menu
Stall Compensation
DWELL TIME
The Dwell Time is the time beween the end of the Ramp Up (start sequence) and Optimisation. The Dwell
Time is settable between 0 and 255 seconds, the default being 8 seconds
Energy Saving Menu
Dwell Timer
DEAD BAND
+7
Dead Band Setting
+3
Target Motor
Efficiency
0
Dead Band
-3
-7
The Dead Band is the area above and below the current operating area (See Optimum
Efficiency) in which Integra will not react to a change in motor loading, thus creating a
'Dead Band' to ensure system stability and although is adjustable will not normally need
to be changed.
Default Settings of +3 and -3 is suitable for most applications and is adjustable between
1 and 7 in increments of 1.
Do not change unless advised by Suresense Technologies or their appointed Distributor.
Suresense Technologies©
Integra 2.2-630 kW Version 3.0
January 2014
51
SLIP TOLERANCE
% Motor Slip
at full load
Slip Tolerance setting
1
Slip Tolerance Band
7
14
% Motor Slip
at no load
The Slip Tolerance Setting will allow the motor to slow down to a set point during a no
load condition before any compensation can take place. This feature allows a higher
level of Optimisation during periods of no load on high inertia applications such as a
flywheel press.
The Slip Tolerance Setting is adjustable between 1 and 14 in increments of 1. The
default setting 7 is suitable for most applications.
STALL COMPENSATION - SLIP TOLLERANCE
Stall Compensation is an adjustable 'block' of voltage that is injected into the motor, at a
certain rate, if the Slip Tolerance set point is exceeded. This feature is required to help
the motor maintain its design speed.
The Stall Compensation is adjustable between 1 and 5 in increments of 1, 1 being the
default level. A higher, more aggressive level should be set for loads such as Injection
Moulding machines.
415
40V
5V
10V
1
2
3
4
Increments Vs Time Setting
30V
50V
Line Voltage
250
Suresense Technologies©
5
Integra 2.2-630 kW Version 3.0
January 2014
52
Proximity Sensor Application
Description of operation/function
The proximity application is used to allow feed back from a proximity sensor in a process to the
SI unit. Some good application examples would be escalators, travelator or conveyor belts,
where the Proximity application is used to switch the motor off when no people or product is
present but re instate the motor when required.
Menu options
Proximity Sensor
Application On/Off
Proximity Sensor
Time to Switch Off
Proximity Sensor
Load Level
Load detection (Travelator used as an example)
The load detection is done in two ways,
1. The sensor is triggered so the SI unit knows there is a person present on the travelator;
the time taken for a person to reach the exit of the travelator is calculated using a stop
watch. The time to switch off is then set accordingly. This part is always active and will
always need to be set up
2. The load level is optional, this offers security to make sure the travelator is empty before
switching off . It compares the current torque level with a preset level. If the current level
is above the preset level, the travelator is considered off load and below on load.
Please see fig 1.1 for an explanation of how the load level is indicated
Where does the sensor get connected
Input 4 which is terminals 7 and 8 on TB1 is used for connecting an external proximity sensor to
the Integra unit. These are no voltage inputs they work on open or closed logic only.
Suresense Technologies©
Integra 2.2-630 kW Version 3.0
January 2014
CA is conduction Angle
,this will track the output
torque and is related to
motor loading.
53
SP is set point, this is user defined
and defines where the on load and
off load point is. IMPORTANT ‘ 2 ‘ is
completely on load. Default; ‘38’ is
completely off load. If CA is Below
SP the timer will count down. If CA
is above SP the timer will reset until
such time CA goes below SP.
Fig 1.1
S1 Open
Cut Out In:
Indicates when the
Proximity sensor is
active.
CA: 38 SP:2
0 Mins 11s
Time to switch off in minutes
and seconds.
Please see timed cut off application document for a more indepth explanation of how the set point and load levels
interact.
Suresense Technologies©
Integra 2.2-630 kW Version 3.0
January 2014
A Sensor is placed at the
beginning of the process. In this
case a light beam is used to
detect people entering the
travelator. If the unit is already
on the Timer is reset. If the unit is
off the motor is started up.
Suresense Technologies©
54
Integra 2.2-630 kW Version 3.0
January 2014
55
Time Cut-Off Application
Description of operation/function
The timed cut-off is used on cyclic applications where the process is left idle for a period of time
and the motor can be switched off saving maximum energy. The timed cut-off as standard has
not got an automatic retrigger, the user will need to restart the machine manually. Example of
applications; Injection Moulding Machines and Mechanical press.
Menu options
A ppli c ati on O n / O f f
Timed Cut Off
Application On/Off
The application must be switched ‘On’ for the Integra to start assuming the new
characteristics of the application.
Ti me to c ut off
Timed Cut Off
Time to Cut Off
The allowed time in min and seconds before the unit switches the application
off.
Cut of f l e ve l
Timed Cut Off
Cut Off Level
This is the level set which defines when the application is off load or on load,
A ddi ti onal O pti ons
Timed Cut Off
Input 4 Trigger
Suresense Technologies©
Input 4 can be used as an override to prevent the Integra from timing out and
switching the process off, this is useful in injection moulding machines where
the hydraulic oil is used to pre-warm the machine. This can be used anywhere
to temporarily stop the time out process if required. This option does not need to
be selected it is always available in normal Timed Cut Off mode. If input 4
trigger is selected then this option is disabled and Input 4 becomes the trigger.
Integra 2.2-630 kW Version 3.0
January 2014
56
Set – up Procedure
The unit must be run in normal energy saving mode initially, this will show the loading cycle of
the process. The C Angle parameter is the most important to note as it tracks the load.
ES: On
M Eff: 54%
C Angle: 38
FIG:1.1
ON load
C angle: 2
Set Point
C angle:
30
Off load
C angle:
38
Fig 1.1; from the information in fig 1.1 the process ( black line)
goes on and off load, the red line being completely off load and
blue being on load. A line is drawn between the two which is
the operating set point, in this case C angle = 30 has been
chosen. Whenever the black line goes above the green line the
time cut off count down is reset. When the black line goes
below the green line the counter starts counting down and if the
process stays below the green line for longer than the counter
the process is switched off.
Suresense Technologies©
Integra 2.2-630 kW Version 3.0
January 2014
57
Set: 30
Cutout In:
Act: 38
0Min 4s
The set point is user defined.
The Actual is governed by the
loading.
Load Above Threshold
Set: 30
Act: 19
Display will indicate when the
process considered on load
Input4 Trigger
Timed cut off can also be used with a trigger on input 4, when input 4 is closed the timer
is reset, when input 4 is open the timer counts down. In this mode the output is always
100% and a feedback is needed from the application feeding into input 4.
Input 4 Open
Cutout In: 0Min 6s
Input 4 Closed
Timer Reset
The Display will indicate the status of input 4
Suresense Technologies©
Integra 2.2-630 kW Version 3.0
January 2014
Stored Energy Application
Description of operation/function
The Stored energy application is designed to work on applications with high kinetic energy
such as mechanical presses with large fly wheels. In these types of applications a large
motor is needed to get the fly wheel started but once running the motor is usually under low
load. The stored energy is similar to the timed cut off but the SI unit will switch the motor off
for a period of time and switch it back on again, energising the wheel. The fly wheel usually
will take 45 min to completely stop, for example: if the motor is switched on for 5 min and
switched off for 10 min you get a reasonable saving. The other advantage is that there are
no starting problems, if the flywheel starts from a stand still there are enormous currents
being drawn. Please also read external sensor section.
Menu options
A ppli c ati on O n / O f f
Stored Energy
Application On/Off
The application must be switched ‘On’ for the Integra to start assuming the new
characteristics of the application.
Pow e r of f Le ve l
Stored Energy
Power Off level
This is the level set which defines when the application is Off load or On load.
Pow e r Dow n Ti mer
Stored Energy
Power Down Timer
The allowed time in Min and Seconds before the SI unit powers down the application.
Pow e r O ff Ti me r
Stored Energy
Power Off Timer
This is the time that the SI units remain off before re-energising the fly wheel.
Pow e r O n Ramp
Stored Energy
Power on Ramp
Suresense Technologies©
The SI will ramp the voltage up to a level set by the power on level parameter.
58
Integra 2.2-630 kW Version 3.0
January 2014
Pow e r O n L e ve l
Stored Energy
Power on Level
The Energising voltage does not necessarily have to be 100% of line voltage, this
parameter set a percentage of line voltage to return to.
Pow e r O n Ti me
Stored Energy
Power on Time
This is the amount of time the SI unit applies the Energising voltage to the flywheel in
Min and Seconds.
Re c over y Ramp
Stored Energy
Recovery Ramp
This is how fast the unit restores the voltage to the motor when a trigger is detected
on input 4 taking the unit back into normal operation.
General Note:
The recovery ramp and Power on ramp should not need to be changed in most cases the
factory default should work fine.
Suresense Technologies©
59
Integra 2.2-630 kW Version 3.0
January 2014
60
Set – up Procedure
The unit must be run in normal energy saving mode initially, this will show the
loading cycle of the process. The C Angle parameter is the most important to note as
it tracks the load.
ES: On
M Eff: 54%
C Angle: 38
FIG 1.1
ON load
C angle: 2
Set Point
C angle:
30
Off load
C angle:
38
Fig 1.1; from the information in fig 1.1 the process ( black line) goes on and off load,
the red line being completely off load and blue being on load. A line is drawn between
the two which is the operating set point, in this case a C angle = 30 has been chosen.
Whenever the black line goes above the green line the power off count down is reset.
When the black line goes below the green line the counter starts counting down and if
the process stays below the green line for longer than the counter the process is
switched off and the secondary process begins
Suresense Technologies©
Integra 2.2-630 kW Version 3.0
January 2014
61
Set: 30
Cutout In:
Act: 38
0Min 4s
The Actual is governed by
the loading.
The set point is user
defined.
Load Above Threshold
Set: 30
Act:19
Display will indicate when
the process considered on
load
External Sensor
A sensor or N/O signal from the application must be connected to Input
4 on the SI unit. This signal must indicate when the application is back in
use and the press ( or similar) needs to return to normal operation.
Sequence of operation
Set: 30
Cutout In:
Switch Off count
down
Suresense Technologies©
Act: 38
0Min 20s
Integra 2.2-630 kW Version 3.0
January 2014
Power Shut Down
Power Load in: 26s
Timer count down that the motor remains
off or.
Ramping Up Voltage
To Motor
The voltage Ramp to the power on level
Power Load
Power Shut Down in: 6s
The time that the load is powered.
Sensor Active
Restore Normal Mode
The normal operation is restored if a signal
is detected on input
Suresense Technologies©
62
Integra 2.2-630 kW Version 3.0
January 2014
63
Eddy Drive Application
Description of operation/function
This application was originally developed for use with eddy current drives on
mechanical presses but can also be used on any process where the motor can be left
in energy saving and return to line voltage when there is a trigger on input 4.
Menu options
A ppli c ati on O n / O f f
Eddy Drive
Application On/Off
The application must be switched ‘On’ for the Integra to start assuming the
new characteristics of the application.
Dw e ll Af ter Tr i gger
Eddy Drive
Dwell After Trigger
This is the time that the process takes to do its work; the output voltage will
remain at line voltage for a period of time set in the Dwell after Trigger. The
dwell time must be longer than the press action time.
Sensor is placed just below the
press tool so when the tool comes
down the SI gets a signal to go to
full voltage
Suresense Technologies©
Integra 2.2-630 kW Version 3.0
January 2014
Pump On - Pump Off Application
Description of operation/function
This Application has been developed for use on Pump Jacks (oil wells), there are two timers
which are programmed. One timer is used for switching the motor off and the second timer is
used for switching the motor on. Oil in the well tends to seep in so it is not necessary to keep
the pump running constantly. This is a very simply way of saving extra energy on Pump jacks,
normal energy saving will also happen whilst the timer is counting down
Menu options
A ppli c ati on O n / O f f
Pump On/Off
Application On/Off
The application must be switched ‘On’ for the Integra to start assuming the
new characteristics of the application.
Ti me to Pump O n
Time to Pump Off
Time On
This timer is used to tell the SI unit how long it must remain off before
commencing pumping again. Max 60 hours – 59 Min.
Ti me to Pump O f f
Time to Pump On
Time Off
This timer is used to tell the SI unit how long it must pump for before turning
off. Max 60 hours – 59 Min.
Suresense Technologies©
64
Integra 2.2-630 kW Version 3.0
January 2014
65
Second Count Down
CA: 38 Seconds: 2s
Cutout In: 0h 29Min
Min/ Hour Count Down
Loading indication
Pump is Off 3s
Next Start: 0h 29Min
Indication that the
Pump has been
turned off
Suresense Technologies©
Indication as to
when next start
will commence
Hours / min /
seconds
Integra 2.2-630 kW Version 3.0
January 2014
66
PARAMETER MENU MORE EXTENDED SOFT START
Extended Software
Dual Ramp
Dual Ramp
Application On/Off
Dual Ramp
Dual Ramp
Profile 1 Pedestal
Dual Ramp
Profile 1 Limit
The Dual Ramp facility is useful for providing a starting
profile for applications with high inertia or varying load, such
as a large conveyor in a quarry. To access this application
enter Special Applications – Dual Ramp. Input 4 must also
be bridged.
Dual Ramp
Profile 1 Ramp
PROFILE 1
.
PEDESTAL VOLTAGE
The Pedestal Voltage (A) is the initial voltage that is applied
to the motor at the moment of switch on. The pedestal
should be set the motor shaft begins to rotate immediately,
increasing the pedestal voltage increases the motor torque
by the square of that value. The pedestal voltage in Profile 1
is adjustable in increments of 1%, between 25 and 50% of
the line voltage.
Dual Ramp
Profile 2 Pedestal
Dual Ramp
Profile 2 Limit
Dual Ramp
Profile 2 Ramp
Suresense Technologies©
Integra 2.2-630 kW Version 3.0
January 2014
67
CURRENT LIMIT TIME
The Current Limit level in profile 1 is set at the Pedestal voltage A and can be held at
that level for a programmable period of time, if 0 time is selected the Ramp Up time will
start immediately from the Pedestal setting.
The Current Limit Time B is adjustable in increments of 1 second, between 0 and 255
seconds. If high starting currents are expected for longer periods of time a larger Integra
may need to be fitted. See Integra manual for starting current ratings.
RAMP UP
The Ramp Up time C is the time taken to reach the Pedestal voltage set in Profile 2. The
Ramp Up time dictates the acceleration torque, and therefore, the acceleration time of
the driven load. Setting a particular Ramp Up time will not guarantee that the motor will
accelerate in the set time. A combination of the moment of inertia, for both the load and
the motor, and the speed/torque curves of both the load and the motor govern the
acceleration time.
The Ramp Up time is adjustable in increments of 1 second between 0 and 255 seconds.
PROFILE 2
.
PEDESTAL VOLTAGE
The Pedestal Voltage D is the voltage that is applied to the motor at the end of the
Ramp in Profile 1. The pedestal should be set to continue the acceleration of the load in
a controlled manner. The pedestal voltage in Profile 2 is adjustable in increments of 1%,
between 25 and 80% of the line voltage.
CURRENT LIMIT TIME
The Current Limit level in profile 2 is set at the Pedestal voltage D and can be held at
that level for a programmable period of time, if 0 time is selected the Ramp Up time will
start immediately from the Pedestal setting.
The Current Limit Time E is adjustable in increments of 1 second, between 0 and 255
seconds. If high starting currents are expected for longer periods of time a larger Integra
may need to be fitted. See Integra manual for starting current ratings.
RAMP UP
The Ramp Up time F is the time taken to reach the full voltage. The Ramp Up time
dictates the acceleration torque, and therefore, the acceleration time of the driven load.
Setting a particular Ramp Up time will not guarantee that the motor will accelerate in the
set time. A combination of the moment of inertia, for both the load and the motor, and
the speed/torque curves of both the load and the motor govern the acceleration time.
The Ramp Up time is adjustable in increments of 1 second between 0 and 255 seconds.
Suresense Technologies©
Integra 2.2-630 kW Version 3.0
January 2014
68
PARAMETER MENU SPECIAL PARAMETERS
SWITCH DE - BOUNCE TIMER
Special Parameters
Switch Debounce Time
The Switch De-bounce Timer delays the start routine by the programmed time after Terminals 1
and 2 on Terminal Block TB1 have been bridged. This ensures Integra will not start until
Terminals 1 and 2 on Terminal Block TB1 have been bridged for the programmed period of time
The Switch De-bounce Timer is enabled as default.
The Switch De-bounce Timer is Programmable between 0.1 and 25 seconds in 0.1 second
increments, the default level is 0.1.
VOLTAGE CONTROL
Special Parameters
Voltage Control On/Off
This parameter enables Integra to attain smaller conduction angles and remains in circuit for the
first 16 cycles of the mains supply, thus fluxing the motor before the Pedestal Voltage is applied.
This prevents any current peaks at the initial switch on.
Voltage Control is enabled as default.
VOLTAGE CONTROL CYCLES
Special Parameters
V Control Cycles
Settable to either 4, 8, 12 or 16 cycles of the mains supply.
Do not change this value unless instructed to do so by Suresense Technologies Ltd or
their agent.
VOLTAGE CONTROL CORRECTION
Adjusts the amplitude of the voltage value.
Special Parameters
V Control Connection
Settable between 0-10, 0 being default.
Do not change this value unless instructed to do so by Suresense Technologies Ltd or
their agent.
VOLTAGE CONTROL PULSE WIDTH
Special Parameters
V Control Pulse Width
Adjusts the width of the firing pulses whichn trigger the thyristors. Settable between 5 and 15.
Do not change this value unless instructed to do so by Suresense Technologies Ltd or
their agent.
BLOCKING TEST
Special Parameters
Blocking Test On/Off
The Blocking Test monitors the Thyristor blocking cycle as part of the overall fault routine.
The deafault is Off
ameter sets the voltage level (A) at which Integra will Ramp
Down to after the Soft Stop command.
Suresense Technologies©
Integra 2.2-630 kW Version 3.0
January 2014
69
Line Voltage %
100
80
65
50
(A)
30
38
0
15
Time in Seconds
The Ramp Down Cut Off is adjustable between 30 and 50% of the line voltage in 1%
CONDUCTION TEST
Special Parameters
Conduction Test On/Off
The Conduction Test monitors the Thyristor conduction cycle as part of the overall fault routine.
The deafault is Off
FAULT TIMER
Special Parameters
Fault Timer On/Off
The Fault Timer monitors general fault conditions and provides a fixed time buffer to allow system
recovery before a fault condition is registered.
The deafault is ON
PHASE ANALYSIS
Special Parameters
Phase Analysis On/Off
The Phase Analysis software module conducts the initial monitoring of the Line rotation, and Motor
Windings, ensuring all three phases are present.
The deafault is ON
Special Parameters
Freq Function On/Off
Special Parameters
Cut Off Voltage (%)
FAULT BYPASS
The Fault Bypass feature when enabled will disable the fault routine after Integra has reached Top of
Ramp. The default setting is disabled.
CUT OFF VOLTAGE
This parameter sets the voltage level (A) at which Integra will Ramp Down to after the Soft Stop
command.
Suresense Technologies©
Integra 2.2-630 kW Version 3.0
January 2014
70
PARAMETER MENU INPUT FUNCTION
TB1 is the terminal block located on the top left hand side of the PCB and is labelled 1 – 8. Input 3 (terminal 5 and 6) is
always frequency select, open for 50Hz and linked for 60Hz.
The inputs below can be programmed as shown if they are not already assigned by a previously selected application or
parameter.
INPUT 1 FUNCTION
This function is the start command and is enabled by bridging terminals 1 and 2 on Terminal Block TB1 and cannot be
changed.
INPUT 2 FUNCTION
Input Function
Input 2
Input 2 function described below is enable or disabled on terminals 3 and 4 on terminal block TB1.
Input 2
Not Assigned
PLUG BRAKING SENSOR
Input 2
Plug Breaking Sensor
Provides an input for a speed sensing relay to detect zero speed on Plug Braking Applications. Close terminals to stop braking
effort.
ES WHEN CLOSED
Input 2
ES off when closed
Close terminals to Enable Energy Saving.
ES WHEN OPEN
Input 2
ES off when open
Open terminals to Enable Energy Saving.
DIRECT ON LINE (DOL) START
Input 2
Direct On Line Start
If the above application is enabled a DOL start is selected by bridging terminals 3 and 4 on Terminal Block TB1. This feature is
useful should a full toque start be required.
Suresense Technologies©
Integra 2.2-630 kW Version 3.0
January 2014
71
INPUT 3 FUNCTION
Input 3 (terminal 5 and 6) is always frequency select, open for 50Hz and linked for
60Hz.
INPUT 4 FUNCTION
Input 4 is automatically assigned by an application and its primary function is to end
secondary optimisation (Energy Saving).
Suresense Technologies©
Integra 2.2-630 kW Version 3.0
January 2014
72
PARAMETER MENU OPTIONS MENU
Main Menu
Parameter Menu
Main Menu
Options Menu
Options Menu
Reset Parameters
Return to
Awaiting Start
Options Menu
Software Version
Reset are you sure?
Enter = Yes Esc = No
Keypad
Reaction Time
Menu Scroll
Reaction Time
Fault History
Erase
Parameter Adjustment
Reaction Time
Fault History
Interrogation
Fault History 1
**************************
Fault History 2
**************************
Fault History 3
**************************
Suresense Technologies©
Integra 2.2-630 kW Version 3.0
January 2014
73
Fault History 4
**************************
Fault History 5
**************************
Fault History 6
**************************
OPTIONS MENU
RESTORE DEFAULT PARAMETER SETTINGS
Enabling this feature will restore all the parameters within the Integra to their default levels.
SOFTWARE VERSION
This parameter displays the Integra software version.
KEYPAD REACTION TIME
This parameter changes the reaction time of the Menu Scroll and the Keypad reaction time, both
are adjustable between 1 and 20. 1 being the fastest.
FAULT HISTORY - ERASE
This parameter will clear all the saved fault history from the Integra Memory.
FAULT HISTORY - INTEROGATE
This parameter will list the last 6 faults related to the Integra in order. The types of faults that can
be listed are as follows.
1.
Line Faults for L1, L2 and L3
2.
Motor Winding Fault
3.
Thyristor Fault for L1, L2 and L3
Suresense Technologies©
Integra 2.2-630 kW Version 3.0
January 2014
74
COMMISSIONING
PRE-COMMISSIONING CHECKS
WARNING
UNITS MUST BE INSTALLED IN ACCORDANCE WITH THE CURRENT
NATIONAL ELECTRICAL CODE
THIS EQUIPMENT MUST BE COMMISSIONED BY QUALIFIED PERSONNEL
ONLY. BEFORE ATTEMPTING TO COMMISSION THE UNIT THE ENGINEER
MUST ENSURE THAT HE OR SHE IS COMPLETELY FAMILIAR WITH THE UNIT
AND THE EQUIPMENT THE UNIT IS FITTED TO.
CHECK THE UNIT IS CORRECTLY MOUNTED AND ENSURE THERE IS
SUFFICIENT SPACE AROUND THE UNIT TO FACILITATE ADEQUATE
AIRFLOW. SEE MECHANICAL INSTALLATION
ATTENTION
TOUS LES APPAREILS DOIVENT ÊTRE INSTALLÉS EN CONFORMITÉ AVEC
LES NORMES ELECTRIQUES NATIONALES.
CET EQUIPEMENT NE PEUT ETRE COMMANDE QUE PAR UN PERSONNEL
QUALIFIE. AVANT DE COMMANDER L'APPAREIL, L’INGENIEUR DOIT
S’ASSURER QU’IL OU ELLE POSSEDE UNE CONNAISSANCE APPROFONDIE
DE L’APPAREIL ET DE L’EQUIPEMENT AUQUEL IL EST DESTINE A ETRE
ADAPTE.
VERIFIER QUE L’APPAREIL A ETE MONTE CORRECTEMENT ET ASSUREZ
VOUS QU’IL RESTE SUFFISAMMENT D’ESPACE AUTOUR DE L’APPAREIL
POUR PERMETTRE UNE BONNE VENTILATION. VOYEZ LES INSTRUCTIONS
D'INSTALLATION.
1.
2.
3.
4.
5.
6.
7.
Ensure that Frequency and Voltage setting is configured correctly.
Ensure that Fans (if fitted) are connected to the correct voltage.
Ensure that a suitable application set is selected.
Check that the unit is connected correctly as per the preceding connection
diagrams.
Ensure any Power Factor Correction Capacitors are connected on the input side
of the line contactor and are only switched in or out before or after starting.
Do not exceed the recommended starts per hour while commissioning.
Start Integra.
a)
b)
c)
Integra should start the motor in a smooth controlled manner.
If the motor is running in the opposite direction reverse two of the motor
phases.
You may be able to improve the start by selecting a different application
set or by changing the relevant parameter using the keypad.
Suresense Technologies©
Integra 2.2-630 kW Version 3.0
January 2014
75
SERVICE AND MAINTENANCE
WARNING
THIS EQUIPMENT MUST BE SERVICED BY QUALIFIED PERSONNEL ONLY.
BEFORE ANY WORK ON THE UNIT IS UNDERTAKEN ALL ELECTRICAL
SUPPLIES MUST BE ISOLATED AND A 5 MINUTE PERIOD OBSERVED TO
ALLOW CAPACITOR FILTERS TO DISCHARGE BEFORE WORKING ON THE
UNIT.
A HIGH VOLTAGE INSULATION TESTER SUCH AS A MEGGER SHOULD ONLY
BE USED TO TEST TO EARTH. TESTING BETWEEN THE PHASES ON THE
INTEGRA MAY CAUSE IRREPAIRABLE DAMAGE TO THE UNIT.
ATTENTION
LA MAINTENANCE DE CET APPAREIL NE DOIT ETRE EFFECTUEE QUE PAR
DU PERSONNEL QUALIFIE. AVANT TOUTE INTERVENTION SUR L’APPAREIL,
TOUTES LES CONNECTIONS D’ALIMENTATION ELECTRIQUE DOIVENT ETRE
ISOLEES ET IL FAUT ATTENDRE 5 MINUTES POUR PERMETTRE AUX
CONDENSATEURS DE FILTRAGE DE SE DECHARGER, AVANT DE
COMMENCER A TRAVAILLER SUR L'APPAREIL.
LES TESTEURS D'ISOLATION HAUTE TENSION TEL QUE LE MEGGER NE
DOIVENT ÊTRE UTILISÉS QUE POUR LA LIAISON A LA TERRE. LES TEST DE
PHASE SUR LE INTEGRA PEUVENT PROVOQUER DES DEGÂTS
IRREPARABLES SUR L’APPAREIL.
GENERAL
Integra Optimisers and soft starters have shown themselves to be very robust and
reliable provided they are used within their design capability. The unit requires very little
maintenance, however the checks listed below should be performed at half yearly
intervals.
i)
Check that the environment has not changed and that no restriction has occurred
to the fan or cooling apertures.
ii)
Check all connections for tightness.
iii)
Check all connections for signs of oxidation. A small amount of non-conducting
grease can be smeared on the power connections to prevent oxidation.
iv)
Check mains and control wiring for signs of deterioration.
v)
Visually inspect the control PCB for signs of deterioration, the PCB can be
cleaned with a dry airline if required.
vi)
Replace fan filters if required.
Suresense Technologies©
Integra 2.2-630 kW Version 3.0
January 2014
76
FAULT FINDING
Before moving to the fault finding procedure the following checks should be performed.
i)
Check that supply and motor cables are connected correctly to the terminals of
the unit. Integra will not work within the delta loop.
ii)
Check external control circuitry.
iii)
All fuses including the semiconductor type (if fitted) should be checked for
continuity with a DVM.
iv)
If an electronic overload is fitted check with the manufacturer that it is suitable for
use with a chopped waveform, some electronic overloads interpret a chopped
waveform as a single-phase condition.
Suresense Technologies©
Integra 2.2-630 kW Version 3.0
January 2014
77
FAULT FINDING PROCEDURE TABLE
FAULT
POSSIBLE CAUSE
LCD Display not
illuminated
i) Mains supply not present, check fuses
Integra will not start,
LCD Displaying 'Line
Fault'
i) Mains supply not present, check fuses
Integra will not start,
LCD Displaying 'Motor
Winding Fault'
i) Motor phase not connected, delta contactor not closed.
Integra will not start,
LCD Displaying
'Thyristor Fault'
i) Short circuit Thyristor.
Integra trips during
running.
i)
ii)
iii)
iv)
Over-temperature trip (TT if fitted)
Motor overload trip
Motor thermistor trip (if fitted)
Faulty control PCB
v)
vi)
Faulty fuse
Short circuit Thyristor(s)
ii) Faulty control PCB
NOTE.
THE CONTROL PCB IS THE LEAST LIKELY ITEM TO DEVELOP A FAULT AND
SHOULD ONLY BE SUSPECTED IF ALL OTHER AVENUES OF INVESTIGATION
HAVE BEEN EXHAUSTED.
FAULTY PCB’S SHOULD BE RETURNED TO THE MANUFACTURER FOR REPAIR
OR REPLACEMENT.
NOTE
LE SYSTÈME DE CONTRÔLE PCB EST L'ÉLÉMENT LE MOINS SUSCEPTIBLE DE
PRÉSENTER UNE DÉFAILLANCE. CETTE POSSIBILITÉ NE DOIT ÊTRE
ENVISAGÉE QUE SI TOUTES LES AUTRES VÉRIFICATIONS ONT ÉTÉ
EFFECTUÉES SANS RÉSULTATS.
LES PCB PRESENTANT UNE DEFAILLANCE DOIVENT ETRE RETOURNES AU
FABRIQUANT POUR REPARATION OU REMPLACEMENT.
Suresense Technologies©
Integra 2.2-630 kW Version 3.0
January 2014
78
TESTING AND REPLACING THYRISTORS
THYRISTOR SHORT CIRCUIT TEST
Before performing this test remove all power connections to the unit. Using a good
quality DVM measure the resistance between the input and output of each Thyristor. A
healthy device will give a reading in excess of 100k ohm. Short circuit Thyristors should
be replaced.
THYRISTOR GATE TEST
Using a good quality DVM measure between the following terminals on the control PCB.
Red phase
Yellow phase
Blue phase
K1-G1 and K2-G2 on Terminal Block TB5
K3-G3 and K4-G4 on Terminal Block TB6
K5-G5 and K6-G6 on Terminal Block TB7
Each Thyristor should give a reading between 6 and 50 ohms; any readings above or
below this figure indicate a damaged Thyristor.
THYRISTOR REMOVAL AND REPLACEMENT – SEMIPACK TYPES
Integra, up to and including the SI 110, the Thyristor switching devices are the isolated
Semipack type and configured as an anti-parallel pair. To remove the Thyristor first
remove the gate/cathode connections from the Thyristor taking care not to damage
them, they are keyed and can only be re-connected correctly, then remove the heatsink
retaining screws.
Remove the shorting copper link from the Thyristor terminals and fit to the new Thyristor.
Smear a light film of heatsink compound on the bottom of the Thyristor and fix to the
heatsink, tightening the retaining screws evenly to a torque of 6 Nm.
Lastly re-connect the gate/cathode connections.
THYRISTOR REMOVAL AND REPLACEMENT – “HOCKEY PUCK” TYPES
Integra SI 132V2 and above use “hockey puck” type Thyristors, two of which are
connected as an anti-parallel pair by sandwiching them between two aluminium
heatsinks.
Each Thyristor is clamped between the heatsinks using a bar clamp. The bar clamp
consists of a high tensile steel bar, two retaining bolts and a centrally located spring
washer assembly retained by a castle nut and tab washer. On no account should the
spring washer assembly be tampered with as this sets the clamping torque of the
Thyristor assembly.
Before unclamping the heatsink modules remove the connection bar/braid between the
two top heatsinks and the buss bar connection.
When dismantling the assembly the retaining bolts should be loosened evenly and
removed, the heatsink assembly is now ready for splitting. Take care to note the polarity
of the Thyristor as incorrect replacement will cause failure, remove the gate/cathode
leads and connect to the new Thyristor.
Suresense Technologies©
Integra 2.2-630 kW Version 3.0
January 2014
79
Smear a light film of heatsink compound onto both sides of the new Thyristor and fit to
the heatsink on the locating pin provided. Fit the top heatsink onto the Thyristor again
using the locating pin provided and tighten evenly the two retaining bolts.
The correct clamping torque is achieved when the spring washers compress enough to
just loosen the tab washer.
Repeat the above for second Thyristor in the assembly.
Replace the connection bar/braid between the two top heatsinks and the buss bar
connection.
Suresense Technologies©
Integra 2.2-630 kW Version 3.0
January 2014
80
DIMENSIONS SI 1/SM – SI 375
E
F
Motor Controller
B
A
INTEGRA
D
Removeable
Gland Plate
C
TYPE
A
B
C
D
E
F
Kg
SI-1/SM–SI-22
SI-30-SI-55
SI-75-SI-110
SI-132-SI-225
SI-260-SI-375
SI-450-SI-630
325
385
448
670
750
315
365
426
655
730
120
227
205
225
265
130
130
305
380
480
80
80
205
271
330
10
10
10
10
10
5
11
21
33
54
Suresense Technologies©
Please contact sales office for further details
Gland Box
+A mm
TBA
TBA
TBA
TBA
TBA